Efficiency of the Casting Process Starts in the Melt Shop

Abstract

Though leading metal casting facilities are converting to newer, more efficient styles of melting furnaces, a majority of the metal casting industry in North America still uses reverberatory (reverb) furnaces. This paper/presentation compares the melting process of efficient shaft/tower style melting furnaces to the common reverb furnace, highlighting the numerous ways in which shaft/tower melting furnaces can save money for the owner and increase the bottom line, while improving metal quality. The primary topic involves a study or comparison of gas consumption and metal loss, which are the two main cost drivers in the melting process. Further advantages of shaft/tower melting furnaces include a reduced environmental impact (CO₂ emissions), higher quality and more temperature stable metal, ease of cleaning, methods of automation, greatly reduced dross and sludge formation, and further savings through energy rebate programs.